US5271521A - Method and apparatus for compensating for changes in viscosity in a two-component dispensing system - Google Patents

Method and apparatus for compensating for changes in viscosity in a two-component dispensing system Download PDF

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US5271521A
US5271521A US07/980,543 US98054392A US5271521A US 5271521 A US5271521 A US 5271521A US 98054392 A US98054392 A US 98054392A US 5271521 A US5271521 A US 5271521A
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United States
Prior art keywords
dispenser
pressure
mixture
liquid polymeric
flow
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US07/980,543
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English (en)
Inventor
Jeffrey S. Noss
Richard P. Price
James W. Schmitkons
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Nordson Corp
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Nordson Corp
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Priority claimed from US07/943,105 external-priority patent/US5332125A/en
Assigned to NORDSON CORPORATION reassignment NORDSON CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: NOSS, JEFFREY S., PRICE, RICHARD P., SCHMITKONS, JAMES W.
Priority to US07/980,543 priority Critical patent/US5271521A/en
Application filed by Nordson Corp filed Critical Nordson Corp
Priority to CA002109376A priority patent/CA2109376C/en
Priority to EP93117785A priority patent/EP0599104B1/de
Priority to DE69326596T priority patent/DE69326596T2/de
Priority to AU50789/93A priority patent/AU668227B2/en
Priority to JP29111093A priority patent/JP3512836B2/ja
Priority to KR1019930024876A priority patent/KR940011052A/ko
Priority to MX9307274A priority patent/MX9307274A/es
Publication of US5271521A publication Critical patent/US5271521A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B7/00—Cleaning by methods not provided for in a single other subclass or a single group in this subclass
    • B08B7/02—Cleaning by methods not provided for in a single other subclass or a single group in this subclass by distortion, beating, or vibration of the surface to be cleaned
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
    • B01F25/40—Static mixers
    • B01F25/42—Static mixers in which the mixing is affected by moving the components jointly in changing directions, e.g. in tubes provided with baffles or obstructions
    • B01F25/43—Mixing tubes, e.g. wherein the material is moved in a radial or partly reversed direction
    • B01F25/431—Straight mixing tubes with baffles or obstructions that do not cause substantial pressure drop; Baffles therefor
    • B01F25/4314—Straight mixing tubes with baffles or obstructions that do not cause substantial pressure drop; Baffles therefor with helical baffles
    • B01F25/43141—Straight mixing tubes with baffles or obstructions that do not cause substantial pressure drop; Baffles therefor with helical baffles composed of consecutive sections of helical formed elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
    • B01F35/10—Maintenance of mixers
    • B01F35/145—Washing or cleaning mixers not provided for in other groups in this subclass; Inhibiting build-up of material on machine parts using other means
    • B01F35/1452—Washing or cleaning mixers not provided for in other groups in this subclass; Inhibiting build-up of material on machine parts using other means using fluids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
    • B01F35/20—Measuring; Control or regulation
    • B01F35/21—Measuring
    • B01F35/211—Measuring of the operational parameters
    • B01F35/2113—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
    • B01F35/20—Measuring; Control or regulation
    • B01F35/21—Measuring
    • B01F35/211—Measuring of the operational parameters
    • B01F35/2115—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
    • B01F35/80—Forming a predetermined ratio of the substances to be mixed
    • B01F35/88—Forming a predetermined ratio of the substances to be mixed by feeding the materials batchwise
    • B01F35/882—Forming a predetermined ratio of the substances to be mixed by feeding the materials batchwise using measuring chambers, e.g. volumetric pumps, for feeding the substances
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B9/00—Cleaning hollow articles by methods or apparatus specially adapted thereto 
    • B08B9/08—Cleaning containers, e.g. tanks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/32—Mixing; Kneading continuous, with mechanical mixing or kneading devices with non-movable mixing or kneading devices
    • B29B7/325—Static mixers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/58—Component parts, details or accessories; Auxiliary operations
    • B29B7/72—Measuring, controlling or regulating
    • B29B7/726—Measuring properties of mixture, e.g. temperature or density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/58—Component parts, details or accessories; Auxiliary operations
    • B29B7/72—Measuring, controlling or regulating
    • B29B7/728—Measuring data of the driving system, e.g. torque, speed, power, vibration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/74—Mixing; Kneading using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
    • B29B7/7404—Mixing devices specially adapted for foamable substances
    • B29B7/7409—Mixing devices specially adapted for foamable substances with supply of gas
    • B29B7/7419—Mixing devices specially adapted for foamable substances with supply of gas with static or injector mixer elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/74—Mixing; Kneading using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
    • B29B7/7404—Mixing devices specially adapted for foamable substances
    • B29B7/7433—Plants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/74—Mixing; Kneading using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
    • B29B7/76—Mixers with stream-impingement mixing head
    • B29B7/7605—Mixers with stream-impingement mixing head having additional mixing arrangements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/74—Mixing; Kneading using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
    • B29B7/76—Mixers with stream-impingement mixing head
    • B29B7/7615—Mixers with stream-impingement mixing head characterised by arrangements for controlling, measuring or regulating, e.g. for feeding or proportioning the components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/80—Component parts, details or accessories; Auxiliary operations
    • B29B7/82—Heating or cooling
    • B29B7/826—Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D11/00—Control of flow ratio
    • G05D11/02—Controlling ratio of two or more flows of fluid or fluent material
    • G05D11/13—Controlling ratio of two or more flows of fluid or fluent material characterised by the use of electric means
    • G05D11/131—Controlling ratio of two or more flows of fluid or fluent material characterised by the use of electric means by measuring the values related to the quantity of the individual components
    • G05D11/132—Controlling ratio of two or more flows of fluid or fluent material characterised by the use of electric means by measuring the values related to the quantity of the individual components by controlling the flow of the individual components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
    • B01F23/40—Mixing liquids with liquids; Emulsifying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0097—Glues or adhesives, e.g. hot melts or thermofusible adhesives

Definitions

  • This invention relates to two-component mixing and dispensing systems and, more particularly, to systems for mixing and dispensing two different polymeric materials which react chemically with one another when combined to form a mixture whose viscosity varies with changes in operating parameters such as temperature, cure time and the ratio of such materials.
  • Two-component polymeric materials such as reactive adhesives, paints, gasket materials, and caulking materials comprise two separate components which react chemically with one another when intermixed.
  • two-component hot melt polymeric materials used in adhesive applications include a polymeric material and a second material such as a hardener. These types of hot melt adhesives, and other two-component polymeric materials, are dispensed from a system in which the two components are supplied in a predetermined ratio from separate metering pumps to a mixer/dispenser where they are intermixed with one another and dispensed onto a substrate. In such a system, if too much of one component is applied, then the characteristics of the combined mixture of such materials are undesirably altered.
  • Another problem which may occur in intermittent operation of two-component mixing and dispensing systems is a loss of flow control of the resulting mixture of the two components. It is desirous to control the flow rate of the resulting mixture dispensed to the substrate. However, during the first few seconds after opening of the mixer/dispenser, the transient imbalance phenomena described above may result in a loss of control of the flow rate of the mixture. Additionally, a loss of precise control of the flow rate of the mixture can occur as a result of changes in density or viscosity of either of the two components due to temperature changes thereof. If the mixture is an adhesive, this may result in less adhesive being applied to the substrate, which, in turn, may affect the bonding of materials.
  • Each back pressure control comprises a bypass flow path around each metering pump and an adjustable pressure regulator contained in that bypass path.
  • each bypass flow path includes a flow control valve which is closed when the dispenser flow control valve is open and vice versa.
  • the adjustable pressure regulator in each bypass flow path is operated either manually or automatically to adjust the pressure at the inlets to the mixer/dispenser when the flow control valve is closed so that such pressure is equal to or a function of the steady state flow pressure at the inlet to the mixer/dispenser when its valve is open.
  • a pressure substantially in excess of the steady state pressure may be required to obtain the desired volumetric or mass flow rate of each component, and therefore the ratio and the total flow rate of the mixture from the mixer/dispenser when its valve is again opened and flow is resumed.
  • control system of this invention is effective to initiate a purge cycle to either clean cured mixture from the mixer/dispenser, or require replacement of the mixer/dispenser, prior to resumption of the dispensing operation.
  • the system therein comprises a pair of metering gear pumps each having an input side connected to a source of one of the two components and an output side connected to an inlet of a mixer/dispenser.
  • the two metering gear pumps supply a predetermined ratio of the two components into the mixer/dispenser at steady state pressure and steady state flow wherein the components are intermixed to form a mixture for deposition onto a substrate.
  • a back pressure control is associated with each metering gear pump which is effective to maintain a predetermined pressure of each component at its respective inlet to the mixer/dispenser.
  • This invention is predicated upon the concept of providing a further control capability in a system of the type described above.
  • This control capability is based on the premise that higher viscosity materials require more force to move than lower viscosity materials.
  • a change in force is required to eject the mixture from the mixer/dispenser at the same volumetric or mass flow rate obtained during steady state operation.
  • the control system herein is provided with inputs corresponding to each of the three system parameters which affect curing, and, hence, viscosity, of the mixture, i.e., mixer/dispenser off time, mixture temperature and the ratio of the two components.
  • the control system includes a computer which employs an experimentally generated look-up table, or a mathematical formula, to determine the appropriate adjustment in pressure of either one of the two components supplied to the inlets of the mixer/dispenser dependent on the sensed parameters.
  • the controller operates the pressure regulator associated with each back pressure control to vary the pressure at which one or both of the two components are supplied to the mixer/dispenser, so that when the valve of the mixer/dispenser is opened an appropriate force is applied to the mixture within the mixer/dispenser to eject it therefrom at the desired flow rate and ratio.
  • control system In the event the change in pressure required to obtain the desired flow rate exceeds operating parameters of the system, the control system is operative to initiate a purge cycle of the type disclosed in U.S. patent application Ser. No. 07/640,043, filed Jan. 11, 1991 to Schmitkons et al, entitled “Method and Apparatus For Cleaning A Mixer", which is owned by the assignee of this invention and the disclosure of which is incorporated by reference in its entirety herein.
  • the control system can provide the operator with an alarm signalling he or she to replace the clogged mixer/dispenser with a new one.
  • FIG. 1 is a diagrammatic illustration of a two-component mixing and dispensing system embodying the invention of this application;
  • FIG. 2 is a cross sectional view of the static mixer in the system of FIG. 1;
  • FIG. 3 is a cross sectional view taken generally along line 3--3 of FIG. 2 illustrating the static mixer in a condition where it is completely cleared of cured material;
  • FIG. 4 is a view similar to FIG. 3 except after a period of operation of the mixer where a layer of cured material has collected on the mixer walls;
  • FIG. 5 is a view similar to FIGS. 3 and 4 except after the application to heat to the static mixer, and after the introduction of flushing material therein to dislodge the cured material;
  • FIG. 6 is a view similar to FIG. 5 wherein the cured material is transmitted out of the static mixer by the purging material;
  • FIG. 7 is a schematic depiction in the form of a flow chart of the operation of the control system of this invention.
  • FIG. 1 The overall construction and operation of the two-component system 10 illustrated in FIG. 1 is provided initially, which, except as specifically set forth below, forms no part of this invention and is fully disclosed in U.S. patent application Ser. No. 07/640,060 mentioned above.
  • the control system of this invention is described separately below in connection with a discussion of pressure control within system 10.
  • Hot melt materials are those materials which are solid at room or ambient temperature but which, upon application of heat, can be converted to the liquid state. When dispensed at ambient temperature, molten hot melt materials quickly return to the solid state.
  • the two-component hot melt system described herein is particularly suited to the application of a two-component hot melt adhesive such as the Curemelt 560 Series two component hot melt manufactured by The Union Camp Co. This system could as well, though, be utilized for mixing and dispensing cold materials and materials other than adhesives, as for example, paints or gasket or caulking materials. Additionally, the system may be used to dispense hot melt solid or foam materials.
  • the two-component mixing and dispensing system 10 comprises two hot melt applicators 12 and 14, two metering pumps 16 and 18, and a mixer/dispenser 20. Additionally, there is associated with each metering pump 16 and 18 a back pressure control means 22, 24, respectively.
  • the hot melt applicators 12 and 14 are two different types of applicators because of the different volumes of material which each is required to melt and pump to the metering pumps 16 and 18 via the interconnecting conduits 26 and 28, respectively.
  • the hot melt applicator 12 is operative to melt and supply under pressure from a pump contained internally of the applicator a first polymeric material which is utilized in less volume than the component supplied from the bulk hot melt applicator 14.
  • One hot melt applicator 12 suitable for melting and pumping to the system the smaller volume polymeric component of this application is completely disclosed in U.S. Pat. No. 3,964,645 issued Jun. 22, 1976 and assigned to the assignee of this application.
  • a bulk melter 14 suitable for melting and supplying under pressure the main or high volume polymeric component utilized in this application is completely disclosed in U.S. Pat. No. 4,073,409 issued Feb. 14, 1978.
  • the metering pumps 16 and 18 may be gear-type, motor-driven pumps operative to supply molten polymeric material via the conduits 26 and 28, respectively, to the dispenser 20.
  • the volume at which each component is supplied to the dispenser 20 is controlled by the speed of the variable speed motors 16a, 18a utilized to drive the gear 16b, 18b of the pumps 16 and 18, respectively.
  • the metering pumps 16, 18 are coupled or linked electrically such that the ratio of the volume or mass dispensed from one metering pump is in proportion to the volume or mass dispensed from the other one.
  • the gear pump 16 the molten polymeric material derived from the hot melt applicator 12 is supplied to the dispenser 20 via a conduit 30 through an air-operated solenoid valve 32 of the dispenser 20.
  • the main or high volume polymeric material is supplied via a conduit 34 to another air-operated solenoid valve 36 of the dispenser 20.
  • the operation of solenoid valves 32 and 36 is controlled by an electrical control 75 which is connected thereto by lines 33 and 37, respectively.
  • these valves 32 and 36 are individually operable to control the flow of two different components into the dispenser 20 where the two different materials are for the first time combined.
  • the two materials flow through a static mixer 40 having an outer wall 41 and an internal mixing element 43 of the type which is operative to repeatedly divide and recombine the mixture in the course of passage through the mixer 40 such that by the time the two components reach the discharge orifice 42 of the dispenser 20, the two components have been thoroughly mixed.
  • a static mixer is illustrated in the Figs. for purposes of describing the purging operation of this invention, but it should be understood that the method and apparatus herein is equally applicable to other types of mixers including dynamic mixers.
  • an electric resistance cable heater 45 is helically wound around the outer wall 41 of mixer 40 where it is permanently brazed into position using a high melting point brazing alloy (not shown).
  • This cable heater 45 preferably includes an internal-type thermocouple connected by a thermocouple lead to a closed-loop feedback control which forms part of the "electrical control" indicated schematically at 75 in FIG. 1. Power leads and a ground line are also connected between the cable heater 45 and the electrical control 75.
  • the thermocouple sends signals to the electrical control 75, as depicted in FIG. 2, which are correlated to the temperature of mixer 40 and are used to control the operation of cable heater 45.
  • one component of the two-component system is a hardener which, when combined with the other component, causes that component to acquire its desired properties.
  • Each back pressure control means 22, 24 includes a bypass flow path 46, 48 around the gear pump 16, 18 with which it is associated.
  • This bypass flow path comprises a flow conduit extending from the discharge side of the gear pump and its conduit 30, 34 to the input side of the gear pump and its input conduit 26, 28.
  • a pneumatically operated flow control valve 52, 52' connected to the electrical control by lines 53 and 55, and an adjustable pressure regulator means 54, 54' connected in series in the bypass flow path.
  • the adjustable pressure regulator means may take the form of a simple adjustable needle valve forming an adjustable restrictor in the bypass flow path 46, 48 or it may take the form of an adjustable pressure regulator valve.
  • the function of this adjustable pressure regulator means 54, 54' is to regulate and control the back pressure in the bypass flow path 46, 48 when the flow control valves 52, 52' are open.
  • each bypass flow path 46, 48 includes an overload pressure regulator in the form of a pressure relief valve 56, 56' connected in parallel with the flow control valve 52, 52' and adjustable pressure control means 54, 54'.
  • the function of the overload pressure relief valve 56, 56' is to bypass liquid from the discharge side of the metering pump to the inlet side in the event that the pressure on the discharge side of the metering pump exceeds a preset pressure substantially above the operating pressure at which the particular component is to be supplied from the applicator 12 or 14 to the dispenser 20.
  • Air pressure is supplied alternatively to the air-pressure operated solenoids 32, 36 of the dispenser 20 and the pneumatically operated flow control valves 52, 52' of the back pressure control means 22 and 24 as determined by electrical control 75. That is, when air pressure is supplied to the solenoids 32, 34 of the dispenser via lines 33 and 37 so as to cause those valves to open and permit flow of liquid to the dispenser, air pressure is supplied via lines 53 and 55 to the flow control valves 52, 52' to close the bypass flow paths. On the other hand, when the solenoids 32, 36 are closed, and flow of valves 52, 52' are opened.
  • the first or smaller volume component polymeric material is supplied in solid form to the hot melt applicator 12.
  • this component is referred to as the smaller volume component, or component "A”, but it could obviously be supplied at the same volume as the second component and still be within the practice of this invention.
  • this material is melted and converted from the solid to the liquid state.
  • This liquid smaller volume component A is supplied via a pump contained in the applicator 12 under pressure to the metering pump 16.
  • the metering pump is operative to supply the molten liquid component A at a desired flow rate to the discharge side of the metering pump.
  • the output flow from the metering pump 16 is routed via the now open flow control valve 52 and pressure regulator means 54 in the bypass flow path 46, back to the input side of the gear pump 16.
  • This bypass flow of component A will continue until the dispenser flow control valve 32 is opened.
  • the high volume or main component, component "B" solid material is melted by the bulk hot melt applicator 14 and is supplied under pressure from a pump contained internally of the bulk melter 14 to the metering pump 18. So long as the flow control valve 36 of the dispenser remains closed, material B continues to flow through the metering pump 18 and then through the bypass flow path 48, through the open flow control valve 52' and the pressure regulator means 54', back to the input side of the metering pump 18.
  • the pressure of the two components A and B at the input side of the dispenser 20 is in the steady state flow condition when the two components are being mixed and dispensed through the dispenser 20.
  • the pressure regulator means 54, 54' are adjusted so as to maintain the pressure at the inlets to the dispenser 20 at about the same pressure as was recorded by pressure transducer and/or pressure read-out gauges 60, 62 on the input sides of the dispenser 20 in the steady state flow condition, i.e., when the flow control valves 32, 36 of the dispenser were open and the flow control valves 52, 52' were closed.
  • the pressure regulator means 54, 54' are automatically adjusted.
  • the adjustable pressure regulator means 54, 54' may be adjusted by utilizing a closed loop control circuit, including a computer or programmable controller as part of the electrical control 75, to manipulate the adjustment of the pressure regulator means 54, 54' so as to maintain the input pressure to the dispenser as a function of the pressure that prevailed during steady state flow immediately prior to the closing of the flow control valves 32, 34.
  • the steady state pressure is determined for each cycle and the valves 54, 54' adjusted accordingly. This can be accomplished by utilizing pressure transducers for the gauges 60, 62 to provide input signals via lines 61 and 63, respectively, to the electrical control 75.
  • the pressure settings of the pressure regulator means 54, 54' may then be adjusted by the electrical control 75 acting on the pressure control means 54, 54' by signals transmitted via leads 72, 74.
  • the pressure reading at the pressure gauge or transducer 60 located at the inlet to the dispenser will be substantially equal to or a function of the steady state flow pressure when there is no material flowing through the dispenser.
  • mass ratio of two components of a two-component mixing and dispensing system in order to have the resulting mixed components have the desired properties.
  • this may be a color or a drying time, or in the case of an adhesive, this may be a desired adhesive property and cure time.
  • mass is a function of volume and density, and since density is a function of temperature, the volume of materials supplied to the dispenser by the metering pumps 16 and 18 must be varied in accordance with the temperature of the components if a fixed mass ratio between the two-component materials is to be maintained.
  • control 75 will cause the variable speed motor 16a to vary the speed of the metering pump by that same 2.5% in order to maintain the same fixed total mass flow rate of materials dispensed from the dispenser 20.
  • temperature measuring devices 64, 66 such as, for example, a thermocouple or an RTD, are provided for utilization in a closed loop control circuit. It is preferred that a temperature measuring device 64, 66 is located within each metering pump to provide an electrical signal indicative of the temperature of the liquid component material contained within the pump. The signals are furnished via leads 69, 71 to the electrical control 75 which may contain a computer or programmable controller.
  • the electrical control 75 also includes drive controls 68 and 70, such as SCR drives, for controlling the speed of the motors 16a and 16b, via lines 77 and 79. In response to the temperature signals from lines 69, 71, the electrical control 75 provides signals to the respective drive control 68, 70 which, in turn, adjust the speed of motors 16a, 16b, accordingly.
  • component A from the hot melt applicator 12 and component B from the hot melt applicator 14 flow through valves 32, 36, respectively, into the dispenser 20.
  • the internal mixing element 43 is operative to repeatedly divide and recombine the components A and B so that they are thoroughly mixed when they reach the discharge orifice 42.
  • the static mixer 40 first begins operation, the intermixed components A and B flow through essentially clear, unobstructed flow paths 72 and 74 defined by the spiral-shaped, internal mixing element 43 of the static mixer 40.
  • components A and B chemically react with one another within the interior 49 of static mixer 40 and at least partially cure therein to form a mixture of increased viscosity.
  • a method for periodically flushing or purging the partially cured mixture of components A and B from the mixer interior 49 to delay the onset of the formation of a layer of cured material 76 of the type shown in FIG. 4 is disclosed in U.S. patent application Ser. No. 07/640,043, which is briefly discussed below.
  • the flushing or purging of the partially cured mixture of components A and B is accomplished as follows.
  • the low volume flow from hot melt applicator 1 is first discontinued by either shutting off the gear pump 16 or bypassing flow from the conduit 30 by operation of the flow control valve 52 in the manner described above.
  • the high volume flow of component B through conduit 34 is utilized to purge or flush the mixer interior 49.
  • Flow of this component B into the static mixer 40 is accomplished as described above, except that such flow is preferably pulsed or intermittently interrupted such as by turning on and off the metering gear pump 18, or by alternately directing the flow of component B into the bypass flow path 48 instead of through conduit 34 as described above.
  • the flow of component B through conduit 34 into the interior 49 of static mixer 40 is preferably allowed to proceed for a predetermined interval, such as about two seconds, and then is discontinued for a predetermined time interval such as about two seconds, so that a pulsed flow of component B is introduced into the mixer interior 49.
  • the pulsed or intermittently interrupted flow of component B or other purging material into the mixer interior 49 effectively flushes away at least a portion of the mixture of components A and B residing within the mixer 40 which has partially cured. It is believed that the pulsed flow of component B into the mixer 40 has the effect of increasing the "effective viscosity" of such material, which, in turn, increases the shear force which the component B flushing material applies to the partially cured mixture within the mixer interior 49. After being injected into the static mixer 40 for a period of about two seconds, it is believed that the flushing material stops or at least slows down during the following two second period when the flow is discontinued. This slowing or stoppage of the movement of component B within the mixer interior 49 increases its effective viscosity.
  • the component B flushing material previously introduced into the mixer 40 is pushed forwardly, and, because of its high effective viscosity, imposes a comparatively high shear force on at least a portion of the partially cured mixture of components A and B in the mixer interior 49.
  • the pulses of the component B flushing material are continued for a sufficient period of time to force at least a portion of the partially cured mixture of components A and B from the mixer interior 49 through the discharge outlet 42.
  • the above-described purging operation has been successfully conducted over a time period on the order of about 30 seconds, or until about one-tenth to one-eighth of a pound of component B has been flushed through the mixer 40.
  • the mixer 40 is effectively cleared of at least some of the partially cured mixture of components A and B which had been building up therein.
  • the mixture of components A and B which is subsequently introduced into the mixer 40 tends to continue to build up along the walls. This is because the velocity profile of the mixture within the flow passages 72, 74 is such that the material at the center of the passages 72, 74 has the highest velocity, while that portion along the walls has a velocity approaching zero which allows it to be deposited with the material already present on the mixer walls. As a result, the layer of cured material 76 gradually continues to increase in thickness until the flow passages 72 and 74 through the mixer interior 49 become so clogged and restricted that little flow can be obtained through the mixer 40 and/or the components A and B are ineffectively mixed together. This condition can be determined by sensing the pressure across the static mixer 40 with a pressure sensor 77 of any commercially available type.
  • the second aspect of the method of this invention is employed to remove the layer of cured material 76 from the mixer walls.
  • the flow of both components A and B to the mixer 40 is discontinued either by shutting off metering pumps 16, 18 or recirculating their flow through bypass flow paths 46, 48, in the manner discussed above.
  • the cable heater 45 or heating coil 49 is then energized to apply heat to the outer wall 41 of mixer 40.
  • the cable heater 45 or heating coil 49 is operated by the electrical control 75 at a temperature of components A and B, but less than their decomposition temperature. Because the outer wall 41 and internal mixer element 43 of the mixer 40 are preferably formed of stainless steel, or other suitable thermally conductive metallic material, the heat from cable heater 45 of heating coil 49 is quickly and efficiently transferred to all of the walls of the mixer 40.
  • the walls of mixer 40 therefore become heated much more quickly than the cured material 76 as a whole which is adhered thereto. This is because such walls are much more thermally conductive then the polymeric components A and B forming the layer of cured material 76.
  • those portions of the layer of cured material 76 which contact the inner surface of outer wall 41 of the internal mixing element 43 of mixer 40 are quickly elevated to a relatively high temperature, whereas the inner portions of the layer of cured material 76 remain at a lower temperature. Having elevated the temperature of the portions of cured material 76 which contact the mixer walls, the shear strength of such material thereat decreases and this reduces the bond or force with which the layer of cured material 76 attaches to the mixer walls.
  • a flow of flushing or purging material is introduced into the mixer interior 49.
  • the flow of component B into the mixer 40 is resumed at high hydraulic pressure and at a normal application temperature to accomplish the flushing operation.
  • the hydraulic pressure at which the component B enters the mixer 40 varies in accordance with the extent of the restriction of the flow passages 72 and 74 caused by the layer of cured material 76.
  • the component B is introduced at a constant flow rate, e.g., about 10 pounds per hour, and when it initially enters mixer 40, the hydraulic pressure is relatively high, e.g., on the order of about 1800 psi. This pressure then decreases to levels on the order of about 200 psi as cured material exits the mixer 40, with component B being supplied at constant flow rate.
  • the flow of flushing material such as component B is effective to first dislodge the layer of cured material 76 from the outer wall 41 and internal mixing element 43 of mixer 40.
  • the layer of cured material 76 fails or breaks away at the mixer walls, instead of at another location along the thickness of such layer of cured material 76, because of the aforementioned reduction of shear strength of the layer of cured material 76 at the mixer walls.
  • the relatively low temperature component B has a high effective viscosity when introduced into the mixer 40 which maximizes the shear force which component B applies to the layer of cured material 76.
  • the component B flushing material transmits the cured material 76 as a slug through the mixer 40 and out its discharge outlet 42. See FIG. 6.
  • the temperature of the mixer 40 is allowed to return to a normal level and resumption of operation of the system 10 can then proceed.
  • a principal aspect of this invention is predicated upon the concept of adjusting the pressure at which components A and B are delivered to the dispenser 20 through lines 30 and 34, respectively, dependent on changes in viscosity of the mixture of components A and B as it cures within the dispenser 20.
  • the cure rate of the mixture of components A and B within the dispenser 20 is dependent on three parameters, namely (1) the ratio of component A to component B; (2) the temperature to which the mixture is exposed within the dispenser 20; and, (3) the residence time of the mixture within the dispenser 20.
  • the system 10 of this invention monitors each of the three parameters mentioned above, and the electrical control 75 is effective to adjust the "off" pressure within the system 10 dependent on such parameters.
  • This "off" pressure is meant to refer to the pressure within lines 30 and 34 which carry components A and B, respectively. Variation of the pressure within lines 30 and 34, as described above, is obtained by the pressure control means 22 and 24, and, in particular, the adjustable pressure regulators 54 and 54'.
  • FIG. 8 a diagrammatic sequence of the pressure adjustment within system 10 is illustrated.
  • this pressure adjustment is intended to compensate for curing of the mixture within the dispenser 20 during periods when the mixture is not being dispensed.
  • Such pressure adjustment is necessary because as the mixture cures within the dispenser 20, it increases in viscosity and therefore a greater force is required to discharge it from the dispenser 20 when dispensing is resumed.
  • Such greater force is provided by increasing the pressure at which components A and B flow through lines 30, 34 so that the mixture is ejected from the dispenser 20 at the desired flow rate upon resumption of the dispensing operation.
  • This box 80 refers to the control sequence exhibited by the system 10 as described in detail above. Adjustment of the "off" pressure during this operation condition is accomplished by the pressure control means 22 and 24 and electrical control 75 as described above, i.e., the pressure regulators 54 and 54' are operated by the electrical control 75 to ensure that the pressure of components A and B at the dispenser 20 is equal to, or a function of, the steady state flow pressure.
  • Constant flow mode refers to normal operation of the dispenser 20 in production wherein either the dispenser 20 is open constantly, or turned on and off intermittently at short intervals so that curing of the mixture within dispenser 20 is insignificant.
  • the electrical control 75 adjusts the off pressure within lines 30 and 34 carrying components A and B in order to compensate for curing of the mixture within dispenser 20. See box 90.
  • the electrical control 75 monitors the three different parameters within the system 10 which affect curing of the mixture within dispenser 20, i.e., the ratio of components A and B supplied to dispenser 20, the temperature of the mixture within dispenser 20 and the residence time of the mixture within the dispenser 20.
  • the ratio of component A to component B is a function of the speed of the variable speed motors 16a and 18a utilized to drive the gears 16b, 18b of the gear pumps 16 and 18, respectively. As the speed of motors 16a, 18a increases, for example, the volume of components A and B introduced into lines 30 and 34 increases.
  • the electrical control 75 sends a signal via lines 92 and 94 connected to variable speed motor 16a, 18a, respectively, for controlling the relative volume or ratio of components A and B being introduced to the mixer/dispenser 20.
  • the temperature of the mixture within dispenser 20 is monitored by a temperature sensor 96 connected by a line 98 to the electrical control 75.
  • the temperature sensor 96 is effective to send a signal to electrical control 75 representative of the mixture temperature.
  • residence time is measured by a timer (not shown) contained internally of the electrical control 75. This timer is activated when the dispenser 20 is first turned off, and measures the total time during which the mixture is present within dispenser 20 before the dispensing operation is resumed.
  • the electrical control 75 is effective to process the signals received from variable speed pump 16a, 18a, from the temperature sensor 96 and from its internal timer, and employ either a mathematical formula or an empirically or experimentally determined look-up table to determine the appropriate adjustment of the pressure within lines 30 and 34 carrying components A and B. Depending upon the sensed parameters, the electrical control 75 automatically adjusts pressure regulator 54 and/or 54' so that the pressure at which the components A and B are supplied through line 30 and 34 to the dispenser 20 increases sufficiently to force the mixture within dispenser 20 outwardly therefrom at the desired flow rate when the dispensing operation is resumed.
  • the electrical control 75 has effectively adjusted the pressure regulators 54 and/or 54' to increase the pressure with which components A and B are directed through lines 30 and 34. This increased pressure within lines 30 and 34 exerts a greater force on the now higher viscosity mixture within dispenser 20, than during steady state operation, so that the mixture is forced out of the dispenser at a predetermined, desired flow rate substantially equivalent to the flow rate obtained before the dispensing operation was interrupted.
  • This same type of adjustment is made by electrical control 75 in the event either of the other two parameters which affect curing of the mixture were also to change, i.e., the relative ratio of components A and B, or the temperature of dispenser 20.
  • the above-mentioned adjustment of the "off" pressure within lines 30 and 34 produces a calculated or empirically determined pressure within lines 30 and 34 which must be exerted to obtain the desired flow rate.
  • This adjustment pressure level is then compared with a predetermined, maximum pressure necessary for safe operation of the system 10 as depicted schematically in box 100. If the adjusted, "off" pressure is too high, as depicted by the line 102 entitled “Yes", the system 10 undergoes a purge operation depicted schematically by the box 104. In other words, if the pressure necessary to obtain the desired flow rate of the mixture within dispenser 20 is too high, the system 10 must undergo a purge operation prior to resumption of the dispensing operation. This purging operation can be accomplished in the manner described above and depicted in FIGS. 2-7, or, alternatively, the dispenser 20 can be physically removed from the system 10 and replaced by a new mixer/dispenser 20 before resumption of operation.
  • the electrical control 75 waits for a dispenser "on” signal as schematically depicted in box 108. If no "on” signal is received, the operating sequence returns to block 82 as depicted by line 107 in FIG. 8. If the "on" signal is received, indicating resumption of the dispensing operation, the system enters the constant flow mode 86 described above. This constant flow mode continues until a dispenser off signal is received, which is depicted schematically by the box 110. The electrical control 75 then resets to the beginning of the sequence described above, as indicated by line 112 in FIG. 8, and operation proceeds as described above. If the dispenser remains on, as depicted by line 114, the constant flow mode of operation continues.
  • the diagrammatic flow chart shown in FIG. 8 illustrates the operation of electrical control 75 in controlling the system pressure to account for curing of the mixture within dispenser 20 during periods when the dispenser is shut off or in the event of a change in the other operating parameters of interest, i.e., temperature and component ratio.
  • the effect of each of the three parameters discussed above on the rate of curing of the mixture will vary for different types of materials and different operating requirements. It is contemplated that an appropriate mathematical formula can be derived for each different type or class of two-component materials to account for the affect of each of the three parameters of interest. Alternatively, the effect of such parameters can be determined empirically and/or experimentally to generate a "look-up" table contained within the software of the electrical control 75 which is utilized to properly adjust the pressure within lines 30 and 32, as required.

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  • Engineering & Computer Science (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Dispersion Chemistry (AREA)
  • Coating Apparatus (AREA)
  • Accessories For Mixers (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
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  • Control Of Non-Electrical Variables (AREA)
US07/980,543 1991-01-11 1992-11-23 Method and apparatus for compensating for changes in viscosity in a two-component dispensing system Expired - Fee Related US5271521A (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US07/980,543 US5271521A (en) 1991-01-11 1992-11-23 Method and apparatus for compensating for changes in viscosity in a two-component dispensing system
CA002109376A CA2109376C (en) 1992-11-23 1993-10-27 Method and apparatus for compensating for changes in viscosity in a two-component dispensing system
EP93117785A EP0599104B1 (de) 1992-11-23 1993-11-03 Methode und Einrichtung zur Kompensation von Änderungen der Viskosität in einem Zwei-Komponenten Abgabesystem
DE69326596T DE69326596T2 (de) 1992-11-23 1993-11-03 Methode und Einrichtung zur Kompensation von Änderungen der Viskosität in einem Zwei-Komponenten Abgabesystem
AU50789/93A AU668227B2 (en) 1992-11-23 1993-11-18 Method and apparatus for compensating for changes in viscosity in a two-component dispensing system
MX9307274A MX9307274A (es) 1992-11-23 1993-11-22 Metodo y aparato para compensar los cambios en la viscosidad en un sistema de dosificacion de dos componentes.
JP29111093A JP3512836B2 (ja) 1992-11-23 1993-11-22 ２成分配量機構における粘度変化を補償する方法および装置
KR1019930024876A KR940011052A (ko) 1992-11-23 1993-11-22 2-성분 분배 시스템에서 점성의 변화를 보정하기 위한 방법 및 장치

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US64006091A 1991-01-11 1991-01-11
US64004391A 1991-01-11 1991-01-11
US07/943,105 US5332125A (en) 1991-01-11 1992-09-10 Method & apparatus for metering flow of a two-component dispensing system
US07/980,543 US5271521A (en) 1991-01-11 1992-11-23 Method and apparatus for compensating for changes in viscosity in a two-component dispensing system

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US64004391A Continuation-In-Part 1991-01-11 1991-01-11
US07/943,105 Continuation-In-Part US5332125A (en) 1991-01-11 1992-09-10 Method & apparatus for metering flow of a two-component dispensing system

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EP (1) EP0599104B1 (de)
JP (1) JP3512836B2 (de)
KR (1) KR940011052A (de)
AU (1) AU668227B2 (de)
CA (1) CA2109376C (de)
DE (1) DE69326596T2 (de)
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CA2109376C (en) 1998-03-31
JPH06210227A (ja) 1994-08-02
EP0599104B1 (de) 1999-09-29
AU668227B2 (en) 1996-04-26
DE69326596T2 (de) 2000-05-18
CA2109376A1 (en) 1994-05-24
EP0599104A1 (de) 1994-06-01
AU5078993A (en) 1994-06-02
JP3512836B2 (ja) 2004-03-31
MX9307274A (es) 1994-05-31
KR940011052A (ko) 1994-06-20
DE69326596D1 (de) 1999-11-04

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